Sinus debrider apparatus

ABSTRACT

A sinus debrider apparatus comprising a housing, a motor mounted in the housing and a cutter head is mounted to the housing. The cutter head frustum conical shaped and defines an interior chamber, a suction passageway and a fluid passageway. A blade holder is mounted to the head and axially aligned with the interior chamber with a blade member being rotatably mounted in the blade holder. A coupling member is mounted in the interior chamber and connects the motor and the blade member to transmit motion from the motor shaft to the blade member. A manifold member defining separate passageways communicates with the suction passageway and the fluid passageway of the head and forms a connection section to hold a flexible tube providing suction and fluid to the cutter head.

This application is a continuation of application Ser. No. 08/422,903filed Apr. 17, 1995 which application is now U.S. Pat. No. 5,685,838.

FIELD OF INVENTION

The present invention generally relates to the field of tissue removaland more specifically relates to sinus debriders used for tissue removalduring sinus surgery.

BACKGROUND OF THE INVENTION

Generally in the field of sinus surgery, arthroscopic cuttinginstruments have been used which instruments have encountered numerousproblems, the primary one being that the instruments clog or jam fromtissue buildup as there is little fluid present at the sinus surgerysite unlike the abundance of fluid which occurs in the joints of a humanbeing. Furthermore, when fluid is used with such instruments, it isexcessively applied at the surgical site. The tissue jamming or cloggingrequires frequent cleaning or substitution of the prior art instrumentswhich is not only time consuming thus increasing the time of theprocedure as well as decreasing the number of procedures possible in agiven operating room facility but also contributes to physician fatiguethus increasing the chances of error.

The following patents constitute representative types of prior artinstrumentation directed toward tissue removal.

The prior art is replete with numerous surgical instruments utilizing acutting tube mounted within an outer cutting housing, the inner cuttermember being hollow and connected to a source of suction. These cuttingtubes either rotate or reciprocate within the outer tube housing.Examples of such cutting instruments are shown in U.S. Pat. No.5,324,301, issued on Jun. 28, 1994, and U.S. Pat. No. 5,286,253, issuedon Feb. 15, 1994, the latter showing a similar apparatus with a toothedrotating cutter. In such instruments, the cut tissue and other severedmaterial is generally aspirated into a chamber which has a suctionremoval conduit communicating perpendicularly with the axis of thetubular cutting member or flow of the surgical debris. In U.S. Pat. No.4,983,179, issued on Jan. 3, 1991, suction is run through the instrumentbody to a trap in the suction source. Another U.S. Pat. No. 4,274,414,issued on Jun. 23, 1981, discloses an arthroscopic cutter having acoupling member with a central chamber which deflects fluid and tissuescut by the cutter into a cutter tube to a suction box. Anotherarthroscopic surgery instrument with a blunt cutter tip and similarconstruction is shown in U.S. Pat. No. 4,203,444, issued on May 20,1990. A variety of cutter tips which can be used with arthroscopicsurgical instruments are shown in U.S. Pat. No. 4,705,038, issued onNov. 10, 1987, which patent also shows a suction source which extendsfrom the cutter tube through the instrument body exiting out the rear. Acutting lipectomy device which has the suction flowing along a rigidtube parallel to the instrument body is shown in U.S. Pat. No. 4,815,462issued on Mar. 28, 1989.

U.S. Pat. No. 5,403,276 issued Apr. 4, 1995 is directed toward acombined tissue removal system which uses a reciprocating cutting bladeand feedback control for aspiration and irrigation circuits used in thesystem. Aspiration and suction is varied to the cutting instrumentthrough a foot pedal which is controlled by the operator to set andmaintain via valving and transducers the aspiration vacuum andirrigation pressure of the system.

Attempts to overcome clogging and jamming of these types of instrumentsdue to collection of tissue and other materials which have been severedfrom the body during cutting while performing the surgical procedure hasbeen to attempt to remove these materials so that they will not have achance to collect in the instrument or pausing during surgery andbreaking down and cleaning the instruments. Unfortunately, the cleaningof these instruments can be difficult and time consuming in a surgicalenvironment.

U.S. Pat. No. 4,108,182, issued on Aug. 22, 1978, shows a surgicalinstrument with a removable cutter head. The cutter head is providedwith a single lumen exterior conduit leading either to the suction orthe fluid source so that fluid or suction can alternately be providedalong the single lumen flexible tube to the hollow cutting tube. U.S.Pat. No. 5,059,204 issued on Oct. 22, 1991 discloses an ocularguillotine cutter placed within a swagged outer needle. The cutting headhas two removable parts, an infusion sleeve which is provided with apassage for transmission of fluid to the cutting site; and an aspirationsleeve provided with a passage which provides for suction which sucksmaterial through the reciprocating cutter tube from the surgical site.The aspiration sleeve fits on the handpiece by a bayonet pin and theinfusion sleeve fits over a collar of the aspiration sleeve in aninterference fit.

The present invention has overcome the problems inherent in the priorart devices by providing a dual passage, removable manifold which can beeasily removed, cleaned or replaced and a double lumen flexible tube.The cutter head body into which the manifold is mounted is also easilyremoved from the apparatus.

The double lumen flexible tube which supplies both the suction and fluidis mounted in a channel cut into the instrument body with the tubeterminating at one end of the removable manifold. Thus, separatepassageways for suction and fluid are provided in the invention. Itshould be noted that in arthroscopic surgery, there is normally a greatdeal of fluid present at the site of the surgery so that fluid is notrequired, but in sinus surgery which is the primary direction of thepresent invention, there is little moisture, so moisture must besupplied to keep the tissue material from clogging up the device.

The instrument is also provided with a nipple projection extending intothe tube channel so that a surgeon can easily grasp the flexible tubeand with slight finger pressure, decrease the amount of suction or theamount of fluid going to the operation site.

SUMMARY OF THE INVENTION

The present invention is directed toward a sinus cutting instrumentcomprising a housing, a motor mounted in the housing and a cutter headmounted to the housing. The cutter head is frustum conical shaped anddefines an interior chamber, a suction passageway and a fluidpassageway. A blade holder is mounted to the cutter head and is axiallyaligned with the interior chamber. A coupling member is mounted in theinterior chamber and connects the motor and the blade member to transmitmotion from the motor shaft to the blade member which is rotatablymounted in the blade holder. A removable manifold member definingseparate passageways communicates with the suction passageway and thefluid passageway of the head and is formed with a connection section tohold a double lumen flexible tube providing suction and fluid to thecutter head and operation site.

It is an objection of the invention to provide a lightweight easilyhandled surgical instrument which can be readily cleaned and/orsterilized.

It is another object of the invention to provide an instrument whichallows the surgeon to manually change the amount of fluid delivered tothe surgical site and the amount of suction applied at the surgicalsite.

It is yet another object of the invention to provide a central suctionchamber in the instrument which deflects tissue and cut materialsdirectly into the suction line for later filtration of the material.

In the accompanying drawings, there is shown an illustrative embodimentof the invention from which these and other of objectives, novelfeatures and advantages will be readily apparent.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the debrider apparatus;

FIG. 2 is a cross section of the debrider apparatus shown in FIG. 1without its cutter assembly;

FIG. 3 is a cross section of the cutter head assembly with cutterassembly;

FIG. 4 is an enlarged side elevational view of the fluid manifold of thedebrider apparatus;

FIG. 5 is a front elevational view of the fluid manifold shown in FIG.4;

FIG. 6 is a rear elevational view of the manifold shown in FIG. 4;

FIG. 7 is a cross sectional view of the fluid manifold shown in FIG. 4;

FIG. 8 is an enlarged cross sectional view of the flexible tube;

FIG. 9 is a top plan view of the outer cutter tube holder;

FIG. 10 is a side elevational view of the cutter tube holder shown inFIG. 9;

FIG. 11 is an enlarged side elevational view of the end of the cuttertube holder shown in FIG. 10;

FIG. 12 is an enlarged side elevational view partially in section of thedrive coupler member;

FIG. 13 is a top plan view partially in phantom of the drive couplermember shown in FIG. 12;

FIG. 14 is a cross section view of the cutter head assembly with cutterassembly;

FIG. 15 is an elevational side view of the cutter tube of the cutterassembly shown in FIG. 14;

FIG. 16 is an enlarged view of the cutter tube tip shown in FIG. 15;

FIG. 16(a) is a front elevational view of the cutter tube tip shown inFIG. 16;

FIG. 16(b) is an enlarged front elevational view of the cutter tube tipshown in FIG. 16;

FIG. 17 is a cross section view of a cutter head assembly with analternate cutter tube embodiment;

FIG. 18 is a side elevational view of the cutter tube used in FIG. 17;and

FIG. 19 is an enlarged side elevational view of the cutter tip of thecutter tube shown in FIG. 18.

DETAILED DESCRIPTION OF THE INVENTION

The preferred embodiment and best mode of the invention is shown inFIGS. 1 through 19.

In the inventive sinus debrider apparatus 20, the instrument isconstructed with a body 30, a cutting head assembly 50 mounted in thebody 30 and a manifold 80 mounted in the cutting head assembly.

The body 30 which serves as the handle of the instrument is preferablyin two sections formed with a motor housing cap 32 and a hand piece 34which are mounted together and secured by screws 36. The hand piece 34defines a stepped cavity 35 which contains a motor 38 and a power andsignal cord 22 connected to the motor. The cord 22 extends out the backof the hand piece. The motor 38 has a drive shaft 40 which extends intoan axially aligned end cavity which the cutter head assembly is seatedin and a corresponding stepped coupler cavity or chamber 53 formed inthe cutter head assembly 50. The drive motor 38 is adapted to rotate theblade member, or cutter or cutting tube 110 at shearing speeds in aclockwise, counter clockwise or oscillation rotation in response tosignals from an outside control foot pedal so that the tissue materialis cut into discrete pieces. The rear of the motor engages siliconebuffer member 42 to hold the motor in place in the cavity 35 and also todamper motor vibrations. A power source and motor control source isshown by block diagram 24 and this source is connected by a power cord22 to the motor 38 to provide both power and signals for operating themotor in forward, reverse and oscillating manner. The power cord 22 runsthrough a smaller diameter section of a stepped chamber 33 cut in themotor housing cap. The hand piece 34 and motor housing cap 32 which formbody 30 are provided with a groove 37 on the outer surface. The groove37 has rounded side walls and an opening into the atmosphere which issmaller in width than the width of the flexible tube so that theflexible tube which has a diameter greater than the opening width may beforced down into the groove and held in place by the inner walls of thegroove. A nipple 39 extends outward from the hand piece 34 into thegroove 37 and engages the flexible fluid supply tube 26. This nippleallows the surgeon to press down on the flexible double lumen tube 26 toreduce suction to the operation site. The groove 37 holds and retainsthe double lumen fluid transmission tube 26 which is in turn fastened tothe fluid conduit connector end 92 of manifold 80 and at its distal endto a suction source such as a vacuum generator 23 and a fluid supplysource 25 as shown in block diagram. The use of outside fluid andsuction sources is well known in the art. The tube functional crosssection as best represented in FIG. 8 has a liquid lumen 27 which isdivided by separating wall 28 from a suction lumen 29.

The cutter head assembly 50 is formed with a frustum conical body 52defining a shoulder 54 and a rear connector tubular portion 56. Theconnector portion 56 snugly fits in the end cavity of hand piece 34 in3-pin bayonet fit with shoulder 54 abutting the planar end surface ofthe hand piece. The body 52 defines a fluid channel 58 and a suctionchannel 60 which communicate at an angle with a central stepped chamber53, chamber 53 being formed in axial alignment in the body 52. A drivecoupler member 62 is mounted in the stepped chamber 53 and engages motorshaft 40 on one end and cutting tube 110 on the other end so that thetorque generated by the motor shaft 40 is transmitted to the cuttingtube 110 or 202. The coupler member 62 has a stepped body of A.B.S.approximately 1.6 inches in length and defines an annular cutting tubeseat 64 on one end which cutting tube seat leads into and communicateswith deflection chamber 66. The cutting tube seat end is chamfered forapproximately 0.03 inches at a 45 degree angle to the center axis to aidin receiving the cutting tube. The rear downstream wall 68 of deflectionchamber 66 is formed into a bevel which keeps debris from the surgeryfrom collecting and jamming in the instrument. The deflector wall 68allows easy transmission of the tissue and other material which has beencut and removed back through suction channel 60 into the suctionmanifold 80. The distal portion of the coupler member which is of alesser diameter than the cutting tube portion is formed with an annularblind bore 70 which forms the motor shaft seat. The coupler member 62 isthus able to be seated within the coupler section of chamber 53 andeasily rotated around within the chamber. Two retainer rings 72 with aviton O-ring 74 placed between the rings are mounted around the rearstepped end of the coupler member and engage the chamber walls of thebody 52 defining the stepped coupler chamber 53. A retainer ring 75 andfront seal 76 are positioned in the forward stepped seal section 55 ofthe coupler chamber to preclude fluid from flowing back from fluidchannel 58.

The manifold 80 is preferably of one piece clear polycarbonateconstruction with a body 82 branching into a tubular fluid conduit 84defining a fluid passage 86 and a suction conduit section 88 defining asuction passage 90. Channels or passages 86 and 90 are angularlyorientated within the body 82 forming a 30 degree bend allowing thedouble lumen tube 26 to be placed parallel to the handle of theinstrument. Both fluid passages are separated and form a tube connectorend 92 as is clearly shown in FIGS. 4 and 7. The double lumen tube 26snugly fits over the end 92 with lumen separator wall 28 of the tubefitting into gap 94 formed in the tube connector end 92. Each lumen ofthe tube is formed with a semicircle configuration with fluid lumen 27being smaller in cross section than suction lumen 29.

The cutter assembly 100 is mounted in the proximal end of coupler cavity57 and is secured in place by an adhesive or other means. The cuttertube holder or outer tube 102 has a polished surface with a knurleddistal end portion and carries within it an end piece 104 which is cutwith flat edges 105 running from a point past the axis of the tube atapproximately an 11 degree angle to form a tissue engagement opening 106and a spherical end 107. The end piece 104 is secured to tube 102 bybrazing, although other means can be used. The end piece runsapproximately 0.570 inches in length. The outer tube 102 has an outerdiameter of 0.134 inches and an inner diameter of 0.1150 inches. Mountedinside the outer tube 102 is a cutting tube 110 which has a sharpenedcutting tip 112 and knurled distal end portion 114. The cutting tubedefines a lumen 111 therethrough communicating between a tissue cuttingsurface 109 at distal cutting tip 112 and deflection chamber 66 adjacentthe proximal end of the cutting tube. The cutting tube is seen in FIGS.15, 16, 16(a) and 16(b). The cutting tip 112 is ground flat, as shown at113 in FIGS. 16(a) and 16(b); 0.007 inches deep and has a closedspherical end 116. The cutting tube 110 has an outer diameter of 0.1149inches or a diameter which is smaller but of close tolerance with theinner diameter of the outer tube with the end mounted in coupler memberbeing knurled so that it is firmly held in the coupler member.

An alternate embodiment of the invention is shown in FIGS. 17 through19. In this alternate embodiment, the instrument construction isidentical with that previously disclosed with the exception that thecutter tube 202 is provided with a cutting tip 204 having a plurality ofteeth 206 with slightly curved sides and rounded bottoms, the crest ofthe teeth extending above the axis of the cutter tube 202.

In operation, the instrument is positioned to cut tissue with thesuction and fluid modes activated. The cutter blade is activated by afoot switch and the surgeon increases or decreases the fluid to thesurgical site by depressing the flexible tube so that the top lumen 27of the double lumen tube is constricted reducing fluid flow.Alternatively, suction is reduced by depressing the flexible tube overnipple 39 to constrict the suction lumen 29 and reduce suction from thesite. Thus, fluid or suction can be manually controlled by the surgeon'shand while rotation of the blade in either direction or an oscillatingmotion is controlled by a foot pedal.

In the foregoing description, the invention has been described withreference to a particular preferred embodiment, although it is to beunderstood that specific details shown are merely illustrative, and theinvention may be carried out in other ways without departing from thetrue spirit and scope of the following claims:

What is claimed is:
 1. A cutting blade assembly for use with a handpiececontaining a motor for driving said cutting blade assembly, said cuttingblade assembly comprisinga head structure having a connector portionadapted to be coupled with the handpiece, a fluid channel and a suctionchannel; an outer tubular member having a proximal end coupled with saidhead structure and a distal end having an opening therein; and an innertubular member adapted to be driven by the motor and having a proximalend received in said head structure, a distal end defining an opening, atissue cutting surface and a flat adjacent and aligned with said tissuecutting surface, and a lumen disposed between said proximal and distalends of said inner tubular member and communicating with said suctionchannel in said head structure, said inner tubular member beingrotatably disposed in said outer tubular member to define an annularspace therebetween and to position said distal end of said inner tubularmember adjacent said distal end of said outer tubular member and toposition at least part of said flat proximal of said opening at saiddistal end of said outer tubular member, a suction passage for removingfluid and cut tissue from the cutting blade assembly being defined bysaid opening at said distal end of said inner tubular member, said lumenof said tubular member and said suction channel in said head structure,and a fluid passage for supplying fluid to said tissue cutting surfacebeing defined by said fluid channel in said head structure, said annularspace between said inner and outer tubular members and said flat wherebyfluid is delivered directly to said tissue cutting surface.
 2. A cuttingblade assembly as recited in claim 1 wherein said distal end of saidinner tubular member terminates in a rounded, closed end, said tissuecutting surface defines said opening in said distal end of said innertubular member and said opening in said distal end of said inner tubularmember extends from said closed end to said flat.